Method of automatically inserting reply means in a mailing piece



Aprll 19, 1966 F. R. RACHEL ETAL METHOD OF AUTOMATICALLY INSERTING REPLY MEANS IN A MAILING PIECE Filed July 26, 1963 JNVENTORS Frank R. Rachel ATTOR John W Sabbagh United States Patent Oflice 3,246,445 Patented Apr. 19, 1966 3,246,445 METHOD OF AUTOMATICALLY INSERTING I REPLY MEANS IN A MAILING PIECE Frank- R. Rachel, Thornwood, and John W. Sabbagh,

Eastchester, N.Y., assignors to R & R Printing Corporation, New York, N.Y., a corporation of New York Filed July 26, 1963, Ser. No. 297,897 4 Cla ms. (CI. 53-29) The present invention is directed to a method of inserting peply means into a pocket formed in a mailing piece or thefililre and, more particularly, to a method of automaticallyfinserting the reply means into the pocket.

In the direct mail industry it is often desirable to combine a letter to an addressee with an insert of some form to be used in replying to the sender. Probably the most familiar type of mailing piece is a sheet of letterhead paper with a business reply card bearing the address of the recipient and the sender fitted into a pocket or similar receiving means in the sheet of paper. Quite often the sheet of paper contains a window which registers with that portion of the reply card bearing the recipients address. In this way the recipients address on the reply card, which will eventually act as the return address when the card is used, serves as the inside addresson the letterhead. Further, if the letterhead is inserted into a window envelope the address on the card also serves as the outside address for the letter. Such an arrangement requires the recipients name to appear only on one item of the complete mailing piece.

There are. many applications for such mailing pieces, in advertising products or services where, a reply is requested, in charitable solicitations where a return envelope 'inay serve as the addressed reply means and in billing various services or products.

However, while such mailing pieces are in demand, they suffer from the handicap that, prior to the conception of the present invention, insertion of the reply means into the letterhead has been a hand operation. With hand, as compared to automatic, insertion there is, relatively speaking, a rather narrow limit to the number of pieces which can be assembled per unit of time, with a resulting adverse effect on the cost of the operation. Additionally, to assure proper registry between the ad-. dress on'the card and the window opening in the sheet of paper, there must be limited tolerances between the card and the pocket. Iif there is too much play, the address will not appear properly aligned in the window opening. On the other hand, if close tolerances are maintained, it will be difficult to insert the card by hand without ripping the pocket. Further, close tolerances will inhibit the speed with which hand insertion can be made.

Another problem which has existed in the past is that of inserting reply means into pockets which have open faced windows. There are two types of windows in envelopes, one the closed faced type having a transparent covering across the window, and the other, the open faced type which does not have any covering. When reply means are inserted into pockets having such open faced windows, there is a tendency for the reply means to jam into the edge of the window opening causing either or both the reply means and the portion of the mailing piece about the pocket to wrinkle and tear.

Therefore, it is the primary object of this invention to provide a method of automatically inserting reply means into a pocket in a mailing piece which will avoid these Pr l s. 1

It is another object of the invention to provide a method of automatically assembling a mailing piece which also incorporates the steps of folding the mailing piece, inserting it into an envelope, sealing the envelope and applying the proper amount of postage.

Still another object of the invention is to afford a method of automatic insertion of reply means into a mailing piece having an open face window whereby the edge of the open face window will not interfere with the insertion of the reply means.

Accordingly, the present invention displays a method of automatically inserting reply means into a pocket formed in a sheet of paper, such as that used for business Ietterheads. Initially, both the reply means and the sheets of paper are piled in individual stacks spaced from one another. The sheets of paper are arranged so that the bottom faces of the sheets lie in a convex plane with the edges of sheets located opposite the entrance to the pockets being disposed in planes positioned above the plane of the entrance to the pockets. Next individual reply means are removed from their stack and conveyed to an inserting position adjacent to and in alignment with the entrance to the pockets in the sheets of paper. As the reply means is moved into inserting position, the mouth of the pocket is opened, and thenes the inserting step proceeds, the interior of the pocket is opened gradually starting at one side of the pocket and working across to the opposite side. When the reply means is fully inserted, the sheet of paper is stripped from the bottom of its stack and is conveyed to a folding station.

From the folding station the assembled sheet of paper and reply means passes through a series of steps in which it is folded, inserted into an envelope, the envelope is sealed and postage applied to complete the entire operation.

The various features of novelty which characterize our invention are pointed out with particularity in the claims annexed to and forming a part of this specification. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which we have illustrated and described preferred embodiments of the invention.

Of the drawings:

The drawings are a series of schematic illustrations depicting the various steps of the method embodying the present invention as follows:

FIG. 1 at the start of an inserting cycle with the reply means being conveyed from its stack toward the inserting position;

FIG. 2 with the reply means in position to be inserted into the pocket;

FIG. 3 with reply means being inserted in the pocket;

FIG. 4 with the reply means fully inserted and the sheet of paper being stripped from the bottom of its stack; and

FIG. 5 showing the steps of folding the sheet of paper, inserting it into an envelope, and sealing and applying postage to the envelope.

Referring now to the drawing, there is depicted a schematic arrangement illustrating the various steps of the method which embodies the present invention. In the drawing sheets of letterhead paper 10 are shown stacked in position to receive the reply cards 24 in pockets 12.

In each sheet of letterhead paper 10 the pocket 12 is formed at one end by a flap folded over upon the sheet of paper. The pocket extends across a portion of one of the short sides 14 of the paper and its width relative to the short side is determined by the width of the reply card. While the size of the sheets of paper 10 may vary, in the drawing they are shown as regular business, letter head size. The preferred, construction of the letterhead 3 paper If) and its pocket 12 is set forth in the co-pending application of W. F. OGorman, Serial No. 272,639, filed April 12, 1963, now Patent No. 3,132,796. In stacked positions the pockets 12 are located on the bottom faces 16 of the sheets of paper with the pocket openings or entrances 18 facing toward the stack of reply cards 24.

The sheets of paper 10 are stacked so that the bottom faces lie in a convex plane curving about an axis parallel with the short sides 14 of the sheet of paper. Both short sides 14 are located in planes spaced vertically above the entrances 18 to the pockets 12. In the drawing the short side 14 of the sheet of paper close to the pocket opening is illustrated supported on an angle support 20 which maintains it at a level above the entrance to the pocket. The disposition of the short sides 14 are important to the effective insertion of the reply cards into the pocket as will be apparent from the subsequent description of the method. It has been found to be preferable to roll the sheets of paper before placing them in stacked position so that they readily adopt the preformed shape shown in the drawings. The sheets are rolled along their long axis with the pocket on the outside of the roll.

Each sheet of paper has a window 22 which opens to the inside of the pocket 12.. This window could be either of the open or closed face type since the method of automatic insertion of the present invention avoids any problem of interference between the edge of the window and the reply card.

Spaced from the sheets of paper is a stack of reply cards 24 which as illustrated are business reply card size. In their stacked position the cards are flexed so that their bottom faces have a slight concave contour parallel with their short edges, see FIG. 1. This slight curvature permits more effective insertion of the card into the pocket. As described in the aforementioned patent application, Serial No. 272,639, the entrance to the pocket is just sufficiently wide to receive the card 24 allowing about a quarter of an inch tolerance. In hand insertion such close tolerance could not be maintained without either a serious reduction in production or a considerable amount of damage to the cards and pockets.

Intermediate the stacks of reply cards and sheets of paper is a conveyor 26 selected from any of the types well known in the art, which picks one card 24 at a time from the bottom of the stack and moves it to a loading position at the opposite end of the conveyor. At the loading position the card 24 is deposited in an inserter 28 which rides forward for placing the card into the pocket. As shown, the inserter has a leading edge disposed above and slightly forward of the leading edge of the card.

Below the inserter 28 is a device 30 for opening the entrance to the pocket 12. In the drawing device 30 is depicted as a pivotally mounted right angle arm.

In FIGS. 4 and to the left of the stack of sheets of paper there are schematic illustrations of a folder 32 and a combination machine 34 for inserting a folded sheet of paper in an envelope and then sealing the envelope and applying postage.

FIGS. 1 to 5 illustrate the various steps of the method embodied in the present invention. As shown in FIG. 1, the insertion cycle commences with a single card being transported from its stack to the loading position adjacent the stack of sheets of paper 10.

In FIG. 2 the card is located in the inserter 28, and the device 30 is pivoting into position to engage the flap of the sheet of paper forming the pocket. As the inserter 28 rides forward toward the pocket, the flap is pulled downwardly by the device 30 opening the entrance to the pocket preparatory to inserting the card. While the step of opening the pocket is shown employing -a pivotally mounted arm, the same step could be effected by suction, by a directed blast of air or by some other similar operation.

With the entrance to the pocket open as in FIG; 3, the

, insertercontinues forward gradually opening the interior of the pocket and carrying with it the card. As shown schematically, the inserter 28 permits the interior of the pocket to be opened first on one edge and then gradually to the opposite edge. This can be accomplished in one way by having the leading edge of the inserter 28'disposed at an angle to the pocket entrance and above the card whereby it enters first on one side of the pocket and then gradually opens the remainder of the pocket as it deposits the card in position. In this manner the sheet of paper above the card is lifted up by the inserter avoiding any interference between the'c'ard and the opposing edges of the window. Further, by opening the. pocket first along one side and then to the opposite side, the possibility of'interference between the inserter and the pocket is also avoided. f

As the card is fully inserted, the sheetof paper is stripped from the bottom of its stack and ejected to a folding station, see FIG. 4' At the s'ame ,tirne the, inserter'28 and the device return to their starting positions for inserting the next card. Withthe card inserted the sheet of paper next passes into the folder32 where it is folded and then into a combination machine 34where it is deposited in'an envelope and the envelope is sealed and postage is applied all in a manner well known in the art. Therefore, by properly positioning the stacks of paper and cards and by the mannerof opening the pocket for the insertion of the card the method of successfully inserting the cards automatically into a pocket in a sheet of letterhead paper can be accomplished.

It should be understood that a number of various means may be employed for carrying out the various steps of this method.

While in accordance with they provisions of thestatutes the invention has been illustrated and described in the best form and mode of operation of the invention now known, those skilled in the art will understand that changes may be made in the form of the apparatus disclosed without departing from the spirit of the invention covered by the claims, and that certain features of the invention may sometimes be used to advantage without a corresponding use of other features.

We claim:

1. A method of automatically inserting rectangular reply means through an entrance into a pocket formed in a rectangular sheet of paper wherein the pocket is formed by an integral flap folded over upon the sheet of paper and the sheet of paper has a Window opening therein registering with the pocket comprising piling a plurality of the sheets .of paper in a stack with said pocketslocated on the bottom faces of the sheets, positioning'the stack of sheets-of paper so that the bottom faces of the sheets lie in a convex plane the axis of curvature of which is parallel with the short axis of the paper, piling the reply means at a point remote from the sheets" of paper and directed toward the entrance to the pocket, conveying each reply means individually to an inserting position adjacent to the entrance to the pocket, initially gradually separating the opposing faces in the interior of the pocket starting at one ofthe edges normal to the axis of curvature by employing inserter means overlying the reply means whereby first the pocket isopened on one side and the window opening is spacedfrom the reply means vby the inserter means for avoiding interference'between the window and reply means, inserting the reply means into the pocket, and ejecting the sheet of-papen=andits inserted reply means from the bottom of the stack. i

2. A method of automatically inserting rectangular reply means through an'entranced-nto a pocket formed in a rectangular sheet of paper wherein the pocket is formed by an integral flap folded over upon the sheet of paper and the sheet of paper has a window opening therein registering with the pocket comprising piling a plurality of the sheets of paper in a stack with said pockets located on the bottom faces of the sheets, positioning the stack of sheets of paper so that the bottom faces of the sheets lie in a convex plane the axis of curvature of which is parallel with the short axis of the paper, piling the reply means at a point remote from the sheets of paper and directed toward the entrance to the pocket and flexing the reply means so that the bottom faces thereof have a slight concave contour in the direction perpendicular to the opening to the pocket, conveying each reply means individually to an inserting position adjacent to the entrance to the pocket, initially gradually separating the opposing faces in the interior of the pocket starting at one of the edges normal to the axis of curvature by employing inserter means overlying the reply means whereby first the pocket is opened on one side and the window opening is spaced from the reply means by the inserter means for avoiding interference between the window and reply means, inserting the reply means into the pocket, and ejecting the sheet of paper and its inserted reply means from the bottom of the stack.

3. A method of automatically inserting rectangular reply means through an entrance into a pocket formed in a rectangular sheet of paper wherein the pocket is formed by an integral flap folded over upon the sheet of paper and the sheet of paper has a window opening therein registering with the pocket comprising piling a plurality of the sheets of paper in a stack with said pockets located on the bottom faces of the sheets, positioning the stack of sheets of paper so that the bottom faces of the sheets lie in a convex plane the axis of curvature of which is parallel with the short axis of the paper, piling the reply means at a point remote from the sheets of paper and directed toward the entrance to the pocket and flexing the reply means so that the bottom faces thereof have a slight concave contour in the direction perpendicular to the opening to the pocket, conveying each reply means individually to an inserting position adjacent to the entrance to the pocket urging the flap which forms the pocket downwardly at the opening thereto, initially gradually separating the opposing faces in the interior of the pocket starting at one of the edges normal to the axis of curvature by employing inserter means overlying the reply means whereby first the pocket is opened on one side and the window opening is spaced from the reply means by the inserter means for avoiding interference between the window and reply means, inserting the reply means into the pocket, and ejecting the sheet of paper and its inserted reply means from the bottom of the stack.

4. A method of automatically inserting rectangular reply means through an entrance into a pocket formed in a rectangular sheet of paper wherein the pocket is formed by an integral flap folded over upon the sheet of paper and the sheet of paper has a window opening therein registering with the pocket comprising piling a plurality of the sheets of paper in a stack with said pockets located on the bottom faces of the sheets, positioning the stack of sheets of paper so that the bottom faces of the sheets lie in a convex plane the axis of curvature of which is parallel with the short axis of the paper, piling the reply means at a point remote from the sheets of paper and directed toward the entrance to the pocket and flexing the reply means so that the bottom faces thereof have a slight concave contour in the direction perpendicular to the opening to the pocket, conveying each reply means individually to an inserting position adjacent to the entrance to the pocket, urging the flap which forms the pocket downwardly at the opening thereto, initially gradually separating the opposing faces in the interior of the pocket starting at one of the edges normal to the axis of curvature by employing inserter means overlying the reply means whereby first the pocket is opened on one side and the window opening is spaced from the reply means by the inserter means for avoiding interference between the window and reply means, inserting the reply means into the pocket, and ejecting the sheet of paper and its inserted reply means from the bottom of the stack to a folding station, folding the sheet of paper with its inserted reply means for insertion into an envelope, inserting the folded sheet of paper into an envelope, and placing postage upon and sealing the envelope.

References Cited by the Examiner UNITED STATES PATENTS 1,543,842 6/1925 Gwinn et a1. 53-488 2,138,250 11/1938 Lee 229-923 2,835,090 5/1958 De Maine 53-189 2,869,302 1/1959 Scott 53-384 X TRAVIS S. MCGEHEE, Primary Examiner.

S. ABEND, Assistant Examiner. 

1. A METHOD OF AUTOMATICALLY INSERTING RECTANGULAR REPLY MEANS THROUGH AN ENTRANCE INTO A POCKET FORMED IN A RECTANGULAR SHEET OF PAPER WHEREIN THE POCKET IS FORMED BY AN INTEGRAL FLAP FOLDED OVER UPON THE SHEET OF PAPER AND THE SHEET OF PAPER HAS A WINDOW OPENING THEREIN REGISTERING WITH THE POCKET COMPRISING PILING A PLURALITY OF THE SHEETS OF PAPER IN A STCK WITH SAID POCKETS LOCATED ON THE BOTTOM FACES OF THE SHEETS, POSITIONING THE STACK OF SHEETS OF PAPER SO THAT THE BOTTOM FACES OF THE SHEETS LIE IN A CONVEX PLANE THE AXIS OF CURVATURE OF WHICH IS PARALLEL WITH THE SHORT AXIS OF THE PAPER, PILING THE REPLY MEANS AT A POINT REMOTE FROM THE SHEETS OF PAPER AND DIRECTED TOWARD THE ENTRANCE TO THE POCKET, CONVEYING EACH REPLY MEANS INDIVIDUALLY TO AN INSERTING POSITION ADJACENT TO THE ENTRANCE TO THE POCKET, INITIALLY GRADUALLY SEPARATING THE OPPOSING FACES IN THE INTERIOR OF THE POCKET STARTING AT ONE OF THE EDGES NORMAL TO THE AXIS OF CURVATURE BY EMPLOYING INSERTER MEANS OVERLYING THE REPLY MEANS WHEREBY FIRST THE POCKET IS OPENED ON ONE SIDE AND THE WINDOW OPENING IS SPACED FROM THE REPLY MEANS BY THE INSERTER MEANS FOR AVOIDING INTERFERENCE BETWEEN THE WINDOW AND REPLY MEANS, INSERTING THE REPLY MEANS INTO THE POCKET, AND EJECTING THE SHEET OF PAPER AND ITS INSERTED REPLY MEANS FROM THE BOTTOM OF THE STACK. 